Shock Absorber Solenoid Housing Structure for Precise Alignment
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Solution Overview
Problem
The existing solenoids in damping force adjustable hydraulic shock absorbers have increased material and processing costs due to projections on the joining member, which also limit the design freedom and axial length, affecting thrust characteristics.
Innovation Solution
A solenoid design with a coil wound into an annular shape, a movable magnetic element, a stator, and an accommodating member with specific end portions for alignment and solder accommodation, reducing the need for projections and allowing for cost-effective and flexible design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a projection is provided on the inner side of the joining member for alignment, then the housing and stator can be aligned axially, but material and processing costs for the joining member increase
Solution Approach 1:
The alignment function is extracted from the joining member and transferred to the accommodating member. The projection is removed from the joining member, and instead, a stepped structure with an abutting surface is provided on the accommodating member to achieve alignment. This separates the alignment function from the joining function, reducing complexity and cost of the joining member.
Solution Approach 2:
The abutting surface on the accommodating member acts as an intermediary element that enables alignment between the housing and stator without requiring modifications to the joining member. This intermediary structure facilitates precise positioning while keeping the joining member simple and cost-effective.
2Manufacturing precision
If a projection is provided on the inner side of the joining member, then alignment is achieved, but the degree of freedom in designing the distance between the housing and the corner portion of the stator decreases
Solution Approach 1:
The alignment constraint is extracted from the joining member and relocated to the accommodating member. This allows the joining member to be a simple cylindrical component without internal projections, thereby increasing design freedom for the distance between the housing and stator corner portion while maintaining alignment precision through the abutting surface mechanism.
3Ease of operation
If the joining member includes an internal projection for alignment, then axial positioning is achieved, but processing complexity and material usage increase
Solution Approach 1:
The axial positioning function is extracted from the joining member and implemented on the accommodating member through a stepped structure with an abutting surface. This simplifies the joining member to a basic cylindrical component, reducing both material usage and processing complexity while maintaining effective axial positioning.
Solution Approach 2:
The accommodating member with its stepped structure serves as a dedicated alignment component that is simpler and more cost-effective than modifying the joining member. This approach uses a dedicated structure on the housing side rather than complicating the joining member, achieving the same positioning function with less complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces material and processing costs while improving design freedom and thrust characteristics, maintaining alignment without increasing axial length.
Implementation Method 1
a coil wound into an annular shape and configured to generate magnetic force by being energized
Data Source
AI summary
A solenoid comprises a mold coil, a housing, a yoke, an anchor, a cylinder, and an armature. The housing and the yoke are connected together with the cylinder intervening therebetween. The housing includes an accommodating tube portion including a first end portion, a second end portion, and a third end portion. The first end portion faces the anchor. The second end portion is axially recessed back from the first end portion and includes an abutting portion that abuts against the other axial end of the cylinder. The third end portion is axially recessed further back from the first end portion than the second end portion and accommodates solder (copper ring) for sealing space between the third end portion and the cylinder.